Regulator



Jan. 5, 1960 T. c. HEATH 2,920,160

REGULATOR Filed Oct. 14, 1957 INVENTOR. 7710MA5 C. H54 TH United StatesPatent 2,920,160 REGULATOR Thomas Heath, Anderson, Ind., assignor toGeneral Motors Corporation, Detroit, Mich., a corporation of DelawareApplication October 14, 1957', Serial No. 690,005

' 8 Claims. (Cl. 200-87) This invention relates to regulators and moreparticularly to regulators that are used for controlling the batterycharging circuit of a motor vehicle.

It is an object of this invention to reduce the cost of manufacture of aregulator by reducing the number of lead wires used in the regulator andby simplifying the internal electrical circuit of the regulator. Thisobject is accomplished by providing a double contact regulator whereintwo contacts are fixed to a common movable support and wherein a thirdrelatively fixed contact is interposed between the two contacts forcooperation therewith. The two contacts are insulated from one anotherand one of the two contacts is electrically connected to the core of theregulator which is at ground potential. The coil winding surrounding thecore also has one end connected to the core and thus directly to ground.

It is another object of this invention to provide a simple andfool-proof adjusting mechanism for adjusting the air gap between thearmature and core of the regulator. This object is accomplished byproviding a contact support for the stationary contact that has anelongated slot, and a tool receiving slot. The contact support is fixedto an extension of the core of the regulator by athreaded fastener thatpasses through the elongated slot and which is threaded into the coreextension. The fastener also passes through an insulator that isinterposed between the core extension and the contact support. Theinsulator has a prying slot that is adopted to receive the end of anadjusting tool. When the threaded fastener is not completely tightened,a pryingtool is passed through the tool receiving slot in the contactsupport to a point where the end of the tool is in the prying slot ofthe insulator. With one end of the prying tool in the prying slot thecontact support may be adjusted relative to the regulator core byengagement of the prying tool with the contact support.

Furtherobjects and advantages of the present invention will be'apparentfrom the following description, reference being had to the accompanyingdrawings wherein a preferred embodiment of the present inventionisclearly shown.

In the drawing:

Figure 1 is an end view with parts broken away of a regulator made inaccordance with this invention.

Figure 2 is a top view of the armature assembly of the regulator shownin Figure 1.

Figure 3 is an exploded view showing the parts that form the fixedcontact assembly of the regulator of this invention.

Figure 4 is a circuit diagram of a battery charging circuit that may beemployed with the regulator shown in Fig. 1.

Referring now to the drawings and more particularly to. Fig. 1 a voltageregulator generally designated by reference numeral is shown. Theregulator comprises a metal base 11 that carries a frame 12 and an ironcore 14. The frame 12 and core 14 are riveted or "ice otherwise securedto the base 11. A coil 15 is wound on core 14 and has one endelectrically connected to core 14 as shown in Fig. 4. The base 11, frame12, and core 14 are all in electrical contact with one another. The base11 also carries a cover 16 which is spaced from the base by resilientsealing member 18. The cover is secured to the base by suitable threadedfasteners (not shown). It will be apparent to those skilled in the artthat the base 11 may also support a current regulator assembly and acutout relay assembly to complement the voltage regulator illustrated.

The frame 12 carries an armature assembly generally designated byreference numeral 20. The armature assembly includes a spring hangermember 22 to which is welded or otherwise secured a member 24 havingears 26. Member 24 is formed of bimetal material which when heatedproduces a force on armature assembly 20 directed downwardly toward thecore, the magnitude of the force increasing with increasing temperature.The armature assembly further includes electrical insulators 30 and 31,and a contact support 32. The spring hanger 22 and contact support 32carry respectively electrical contacts 34 and 36. The spring hangermember 22 with attached bimetal member 24, insulators 30 and 31, andcontact support 32'are held in fixed relationship with one another byrivets 38.

The armature assembly 20 is secured to the upper end of frame 12 bywelding or otherwise securing the cars 26 of bimetal member 24 to theframe. With this arrangement the ears 26 form a'pivotal connection forthe armature assembly 20 with respect to the frame 12, the pivot pointof the armature assembly being the point of attachment of the ears 26with the top end of the frame. The armature assembly 20 is biasedupwardly in a clockwise direction by a tension spring 40 that has oneend looped over the end of spring hanger member 22 and has another endattached to a bracket 42 that is secured to the frame 12. When theregulator-temperature rises due to external or internal heating effectsthe bimetal member 24 produces a force acting on armature assembly 20 inopposition to the bias of spring 40. This compensating effect isnecessary to compensate for the reduced flux output or ampere turns ofcoil 15 when the coil temperature rises. The effective ampere-turns ofcoil 15 are reduced when the coil temperature rises because of theincrease in electrical resistance of the coil which reduces the currentflow therethrough for a given voltage. The compensating force producedby bimetal member 24 acts against the force of spring 40 and thus lessflux is required to attract armature 20 when the bimetal member isheated.

The voltage regulator is also compensated for temperature change by amagnetic shunt member 43 that is suitably secured to core 14 and whichextends to a point just short of, or touching frame 12. The member 43 isformed of a material having a negative temperature coeflicient ofpermeability such as nickel-steel. When the temperature of the shuntmember 43 and coil 15 increases, the permeability of shunt member 43changes to shunt less magnetic flux away from armature assembly 20. Inthis manner, the shunt member 43 with its varying coeflicient ofpermeability compensates for changes in temperature. The bimetal 24 andshunt member 43 thus provide for a two-fold method of temperaturecompensation for the regulator shown.

The fixed contact assembly of the voltage regulator is generallydesignated by reference numeral 44. This assembly includes a metalbracket 46 that is press fitted or otherwise secured to core 14. Theassembly further includes an insulator member 48 formed of nylon or-thelike that is U-shaped in cross section and which has a tool receivingrecess '50 and a button 51. The assembly voltage regulator .10.described above.

also includes a metal contact support 52 that has an elongated opening53 and a second opening 55. The contact support is slidably fittedbetween the sidewalls 59 of insulator 48 and .carries contacts 54 and 56that are in electrical contact with support 52 and which are interposedbetween contacts 34 and 36. The parts of the fixed contact assemblybefore being secured together are illustrated in Figure 3.

The insulator 48 and contact support 52 are 'held in the relationshipshown in Figure l by a screw 58 that is threaded into support 46. Thescrew is threaded or press fitted in nylon insulator 48 and passesthrough opening 53. The screw 58 is insulated from contact support 52 byan insulating washer 60 and by button 51. The core 14 is thuselectrically insulated from the fixed contacts 54 and 56 by insulator 48and insulating Washer 69. The arrangement just described provides foreasy adjust- .ment of the air gap distance between hanger 22 and thetopend of core 14.

In order to adjust the contact support 52 upwardly or downwardly toeffect the adjustment described, the

.screw 58 is first backed out slightly to loosen the connection betweenthe insulator 48 and contact support 52. When the connection is thusloosened the end of a tool such as a screwdriver 62 is passed throughthe slot 55 of contact plate 52 and the end of the screwdriver is fittedinto the recess 50 formed in nylon insulator 48. When the screwdriver isso positioned it ma 1 be moved upwardly or downwardly with the insulator48 providing a fulcrum for the screwdriver. The contact plate is notimpeded in its adjusting movement by screw 58 because of the clearanceprovided by opening 53 above and below button 51. The contact support 52slides between the sidewalls 59 of insulator 48 which guide the supportin its movement. The limit of adjustment is reached when the internalwalls of opening 53 engage the button 51 on insulator 48.

It will be apparent from the foregoing that a double contactsperiodically engage relatively fixed contacts 54 and 36 are insulatedfrom each other and wherein these contacts periodically engagerelatively fixed contacts 54 and 56 on contact support 52. The contacts34 and 54 are normally held in engagement with one another by spring 40when coil 15 is not energized sufiiciently to attract armature 20against the bias of spring 40.

to a point where contact 36 engages contact 56 and contact 34 leavescontact 54. When the regulator is used in the circuit shown in Figure 4the armature 20 at times vibrates so that contacts 34 and 54 becomeintermittently engaged and during this vibration the contacts 36 and 56do not engage. At other times the contacts 34 and 54 are intermittentlyengaged due to vibrating movement of armature assembly 20 withoutengagement of contacts 36 and 56. The regulator thus operates by theswitching action of either contacts 34 and 54 or by the switching actionof contacts 36 and 56 depending upon the energization of coil 15.

A preferred circuit arrangement for use with the volt age regulatordescribed is shown in Figure 4. In this figure, the same referencenumerals as those used in 64 while the other side ofthe .field windingis connected with a resistor 67 b 'a lead 68.

.Theregulating apparatus forthe generator 63 shown in 'Figure 4 includesa conventional cut-out relay general- .ly designated by referencenumeral 7, a current regulator generally designated by reference numeral71, and the The cutout, relay When coil 15 is energized sufficiently toovercome the bias of .spring 40 the armature assembly 20 movesdownwardly includes an iron core 72, an armature 73, switch contacts 74,shunt coil winding 75, series coil winding 76, and a frame designated byreference numeral 77. The current regulator 71 includes iron core 78,series coil 79, armature 80, and contacts 81. The voltage regulator 10shown in Figure 4 is identical with the regulator shown in Figures 1, 2and 3.

The contacts 74 of cutout relay 70 are normally held open by resilientmeans (not shown) in accordance with conventional regulator practice.When a predetermined voltage is impressed across coil 76 the armature 70is attracted to close contacts 74. The contacts 81 of current regulator71 are normally held closed by resilient means (not shown). When apredetermined current passes through coil 79 the armature is attractedtoward core 78 to open the contacts 81. The voltage regulator 10operates in the fashion described above.

One side of the armature 64 of generator 63 is directly connected tocoil 79 of current regulator 71 by a lead 82. The opposite side of coil79 is connected to one side of series coil 76 of cutout relay 70 by alead 83.

'The opposite side of series coil 76 is connected directly to frame 77which is in electrical contact with armature 73. The shunt coil 75 ofcutout relay 70 is connected between the armature 73 and ground.

The contacts 74 of cutout relay 70 are connected between armature 73 anda lead 84 that is connected to one side of a storage battery 85. Theopposite side of the storage battery is connected directly to ground asshown. The charging current for battery passes through lead 82, throughcoil 79 of current regulator 71, through lead 83, through coil 76,through frame77, through armature 73, through contacts 74, and throughlead 84 to the battery 85. The contacts 74 are maintained open until thegenerator is producing a predetermined voltage whereupon theenergization of coils 75 and 76 pulls the armature down to closecontacts 74. The contacts 74 remain closed as long as the generator isoperating.

One side of shunt coil 15 of voltage regulator 10 is connected directlyto the iron core 14 of regulator 10. The opposite side of coil 15 isconnected to one side of resistor 86 by a lead 87. The opposite side ofresistor 86 is connected to frame 77 of cutout relay 70 by a lead '88.The armature part 32 of voltage regulator 10 is connected with armature73 of cutout relay 70 by a lead 89. One of the two contacts 81 ofcurrent regulator 71 is connected to the fixed contacts 54 and 56 ofvoltage regulator 10 by a lead and is also connected with core 78 ofcurrent regulator 71. The other contact 81 is connected with lead 68 andresistor 67 by a lead 91. The lower movable contact 34 of voltageregulator 10 is connected to core 14 via frame 12. The core 14 ofvoltage regulator 10 is connected directly to ground by a lead 92. Theside of resistor 67 opposite from the side connected with lead 68 isconnected to iron core 78 of current regulator 71 by a lead 93. Aregulating resistor 94 is connected between the lead 93 and ground asshown, and thus is connected between core 78 and ground.

It will be observed that the shunt winding 15 of voltage regulator 10 isconnected in series with resistor 86 and across the output terminals ofthe generator 63. This circuit may be traced from armature 64, via line82, coil 79 of current regulator 71, line 83, series coil 76 of cutoutrelay 70, frame 77, lead 88, resistor 86, lead 87, coil 15, and throughcoil 14 to ground. The shunt coil 15 is thus always connected across thearmature 64 and responds to the output voltage of the generator.

As noted hereinbefore, the voltage regulator either operates on thelower set of contacts 34 and 54 or on the upper set of contacts 36 and56. Whether operation is on the upper or lower contacts depends ontheamount of load being supplied and ..upon the speed the armature 63 isdriven by the engine of a motor vehicle. When the voltage regulatoroperates on the lower set of contacts '34 and 54 the armature assembly20 vibrates to periodically open and close these contacts. When thevoltage across coil is above some predetermined value the armature isattracted to opencontacts 34 and 54. In this position of the armature 20and spring hanger 22 the field 65 of generator 63 is connected in serieswith regulating resistor 94 across armature 64 to reduce the fieldcurrent. This circuit may be traced from armature 64, through field 65,via line 68, line 91, contacts 81, core 78 of current regulator 71, line93, and through resistor 94 to ground.

When the voltage across ,coil 15, falls below some predetermined valuethe spring 40-closes contacts 34 and' 54 against the attractive force ofcoil 15. When contacts 34 and 54 are. closed the regulating resistor isshorted out and field 65 is connected directly across generator 63 toprovide for increased field current. This circuit may be traced fromarmature 64, via ,field 65, line 68, line 91, contacts v.81, line 90,contacts 54 and 34, frame 12, and through core 14., to ground. It is tobe noted here that the circuit for field 65 is made directly throughcore 14 which is grounded and via spring hanger 22 which is inelectrical contact with core 14 via frame 12.

When the voltage regulator is operating on the upper set of contacts 36and 56 the contacts 36 and 56 are periodically open and closed byvibration of armature 20 and contact support 32. When the voltage acrosscoil 15 is below some predetermined value the spring 40 holds contacts36 and 56 open. With contacts 36 and 56 in an open position the resistor94 is again connected in series with field 6,5 to provide for apredetermined value of field current. This circuit may be traced viaarmature 64, field 65, line 68, line 91, contacts 81, armature 80, core78, line 93 and through resistor 94 to ground. When the voltage acrosscoil 15 increases the armature 20 and contact support 32 are attractedto close contacts 36 and 56. This reduces the field current below thevalue which obtains when contacts 36 and 56 are open by substantiallyshort circuiting the field 65. It will be appreciated that in eitherupper or lower contact operation the contacts are made and opened byrapid vibration of armature 20.

When the current through coil 79 of current regulator 71 exceeds somepredetermined value the armature 80 is attracted to open contacts 81.With contacts 81 in an open position the resistor 67 is placed in serieswith field 65 across armature 64 to reduce the field current. When thecurrent through coil 79 is at a normal value the contacts 81 remainclosed. With contacts 81 closed the resistor 67 is shorted out and thefield 65 is connected directly across the armature 64 of generator 63 toincrease the field current. The contacts 81 open and close rapidly byvibration of armature 80 when the current regulator is operating.

While the embodiments of the present invention as herein disclosedconstitute a preferred form, it is to be understood that other formsmight be adopted.

What is claimed is as follows:

1. A regulator comprising, a metal base, a metal frame secured to saidbase in electrical contact therewith, a metal core member carried bysaid base in electrical contact therewith, a coil Winding on said corehaving one end thereof connected with said core, a first pair of fixedcontacts connected together which are supported by said core andinsulated therefrom, an armature assembly including second and thirdspaced apart contacts that are insulated from each other, meanspivotally connecting said armature assembly to said frame with saidsecond and third contacts being located at opposite sides of said firstpair of fixed contacts for alternate engagement therewith, and meansconnecting one of said second and third contacts in circuit with saidmetal core.

2. A regulator comprising, a base, a coil winding assembly including acore and a coil winding supported by said base, an armature carrying afirst contact overlying said core and mounted for pivotal movement withrespect to said core, a contact supporting plate formed recess.

6 of current conducting material having a second contac t positioned toengage said first contact in one position of said armature, a bracketmounted in fixed relationship to said core, a first elongated slot insaid contact supporting plate, a second tool receiving slot in saidcontact supporting plate spaced from said first slot, an insulatormember having a recess, and a threaded fastener passing through theelongated slot in said contact supporting plate and through saidinsulator member into said bracket, said tool receiving slot in saidcontact supporting plate and said recess in said insulator being inalignment with one another whereby said contact supporting plate may bemoved relative to said insulator and bracket by the prying action of atool that is adapted to be passed through said tool receiving slot andinto said insulator 3. In combination with a regulator having a coilwinding assembly that includes a metal core and a coil winding, anarmature carrying a first electrical contact located adjacent said coreand adapted to be magnetically attracted by said coil winding assembly,said armature being mounted for movement toward and away from said core,a support fixed to said core, an insulator member abutting said support,a metal contact supporting plate having an elongated slot carrying asecond electrical contact abutting said insulator with said secondcontact being located in position to engage said first contact, afastener passing through said elongated slot and secured to saidsupport, a tool receiving slot in said contact plate, and shoulder meanson said insulator located in alignment with said tool receiving slot.

4. Adjusting mechanism for a regulator of the type having an actuatingcoil and a movable armature that carries a first electrical contactcomprising, fixed support means, a contact supporting plate locatedadjacent said fixed support means and having a second contact positionedto be engaged by said first contact, means for slidably supporting saidcontact plate for movement relative to said fixed support means, a slotin said contact plate, and shoulder means on said fixed support means insubstantial alignment with said slot.

5. A regulator comprising, an actuating coil assembly including a metalcore and a coil winding, a first pair of electrical contacts supportedby said core, and an armature assembly including second and thirdcontacts secured to and separated by an insulator, mounted for pivotalmovement, said second and third contacts being disposed on oppositesides of said first contacts for cooperation therewith.

6. A regulator comprising, a metal base, a frame secured to said base, acore element carried by said base, an armature assembly including a pairof contact supports separated by an insulator pivotally secured to saidframe and overlying the top end of said core, first and second contactscarried respectively by said contact supports, a bracket carried by saidcore, an insulator member abutting said bracket, a metal contact platecarrying a third contact slidably engaging said insulator member, saidthird contact being disposed between said first and second contacts forengagement therewith, an elongated slot in said contact plate, athreaded fastener passing through said slot having a portion engagingsaid contact plate and a portion threaded into said insulator member andbracket, a second slot in said contact plate spaced from said elongatedslot, and shoulder means on said insulator located in substantialalignment with said second slot whereby a tool may be passed throughsaid second slot and into engagement with said shoulder means foradjusting said contact plate by a prying action with the shoulder meansacting as a fulcrum for the tool.

7. A regulator comprising, a base, a coil winding assembly supported bysaid base and including a core and a coil winding, a frame secured tosaid base, an armature member carrying an electrical contact, a bimetalspring member secured to said frame and to said armature member and.forming a pivotal connection for said armature withv respect to saidframe, said bi-metal spring member supporting said armature member incantiliver fashion over said core, a second spring having a portionfixed with respect to said frame and having a portion connected withsaid armature member for urging said armature member away from saidcore, a fixed contact adapted to be engaged by the contact carried bysaid armature, and a magnetic shunt member formed of material whosepermeability changes with temperature supported by said core andextending toward said frame.

8. A regulator comprising, a base, a frame supported by said base, anactuating coil assembly including a core and a coil winding supported bysaid base, an armature assembly pivotally supported by said frame andoverlying said core, said armature assembly including first and secondspaced arms each carrying an electrical contact, an insulator positionedbetween said arms for electrically insulating one arm from the other, apair of electrical contacts connected together and positioned ReferencesCited in the file of this patent UNITED STATES PATENTS 1,968,971Sullivan Aug. 7, 1934 2,135,977 Leece NOV. 8, 1938 2,225,158 CrawfordDec. 17, 1940 2,306,893 Menzel Dec. 29, 1942 2,623,965 Clark Dec. 30,1952 2,723,323 Niemi Nov. 8, 1955 2,728,033 Robinson et al. Dec. 20,1955 2,758,176 Harrold Aug. 7, 1956 2,788,412 Heath Apr. 9, 19572,814,690 Zimmer Nov. 26, 1957

